Left Fuel Tank Chamber With Attachments
Left Fuel Tank Chamber with Attachments
Special tools, testers and auxiliary items required
• Pry Lever - Rmv Outside Mirror (80 - 200)
• Hose Clip Pliers (V.A.G 1921)
• Fuel Extracting Device (VAS 5190)
• Wrench (T10202)
Removing
- Observe safety precautions. Refer to => [ Safety Precautions ] Safety Precautions.
- Observe rules for cleanliness. Refer to => [ Clean Working Conditions ] Clean Working Conditions.
- Slide the driver's seat forward as far as possible. Then fold the backrest forward.
CAUTION!
Risk of destroying electrical components when battery is disconnected.
• Observe measures when disconnecting battery.
- With the ignition switched off, disconnect the battery ground (GND) - arrow -.
- Removing engine.
CAUTION!
Danger due to escaping fuel.
• Fuel tank must be empty.
• The following procedure drains the fuel tank about 90%. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
• When removing the left fuel tank chamber, open the left locking flange and drain the remaining fuel through the opening in the fuel tank chamber.
- Fuel Tank, Emptying. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
R8 Coupe
- Remove left side trim panel.
- Remove the right rear connector station from the control module bracket and lay it aside.
- Disconnect the control module electrical connectors and remove the control module bracket - arrows - from the vehicle.
- Press the electrical wiring harness off the rear bulkhead using (80 - 200) and free it up.
R8 Spyder
- Remove the cover module.
All Vehicles
- Fold the insulation mat over the connection seal cover.
- Remove the left and right bolts on the locking flange cover - 1 to 4 - and then remove the cover.
- Disconnect the electrical connector - arrow - on the left locking flange.
- Disconnect the fuel lines - 1, 2, 3 - on the left locking flange by pressing the release buttons.
• Depending on the version, there may be 2 instead of 3 lines.
- Disconnect the fuel lines - 1, 2, 3 - on the right locking flange by pressing the release buttons.
• Depending on the version, there may be 2 instead of 3 lines.
• Disregard - arrow -.
CAUTION!
Danger due to escaping fuel.
• To prevent large quantities of fuel from spilling out when removing the left locking flange, empty the fuel tank. Refer to => [ Fuel Tank, Draining ] Fuel Tank, Draining.
- Disconnect the left locking flange locking rings using (T10202).
- Lay the left locking flange - 1 - with the fuel lines still connected to the side.
- Extract the fuel in the left fuel tank chamber through the opening using the (VAS 5190).
- Install left locking flange => [ Installing ] Fuel Level Sensor 4.
R8 Coupe
- Loosen bolts - arrows - a few turns.
- Remove bolt - 2 - and remove the left engine control module bracket - 1 -.
- Disconnect the fuel line - 1 - on the fuel filter by pressing the release button.
- Disconnect the vent line - 2 - from the left fuel tank chamber by pressing the release button.
- Remove the secondary air injection pump.
R8 Spyder
- Press the release buttons and remove fuel lines - 1 and 2 - to the fuel filter.
- Press the release button and disconnect the bleed line - 3 - to the left fuel tank chamber.
- Free up the bleed line on the bracket - arrow -.
All Vehicles:
- Disconnect the engine oil cooler coolant hoses and lay them to the side.
- Remove the oil line for the engine oil cooler.
- Remove brake booster vacuum line.
- Remove the power steering hydraulic oil lines.
- Remove nuts - 1 - and - 2 -.
- Remove the bolts - arrow - and remove the left fuel tank chamber heat shield.
- Disconnect the coolant hose on the rear panel from the bracket and lay it to the side.
- Remove nuts - 1 - and - 2 -.
- Remove the bolts - arrows - and remove the left fuel tank chamber heat shield.
CAUTION!
Risk of damaging coolant lines and hoses.
• Do not stretch, kink or bend coolant lines and hoses.
- Disconnect from the compressor the refrigerant line, which leads to the A/C accumulator at the separating point - 3 - and remove.
- Remove the refrigerant line retaining clamp screw - 2 -.
- Remove the A/C accumulator - 1 - from the bracket with the refrigerant line still attached and lay it to the side.
- Remove bolts - 1 through 3 - and the upper left longitudinal member.
- Disconnect the upper ground (GND) connection connector - arrow - on the fuel tank chamber.
- Remove the fuel supply line and suction jet pipe - 1 -.
CAUTION!
Danger due to escaping fuel.
• Remove the connection hose - 2 - only when the fuel tank is empty.
- Loosen the hose clamps and disconnect the connection hose - 2 -.
R8 Coupe
- Remove bolts - arrows -, remove tensioning straps - 1 - and - 2 -.
All Vehicles
CAUTION!
Danger of damaging the fuel line connections
• When removing the fuel tank chambers, make sure the connections to hang on the body.
- Swivel the fuel tank chamber by the rear edge toward the center of the vehicle and remove.
Installing
• Tightening specifications, refer to => [ Fuel Tank with Attachments Assembly Overview ] Fuel Tank With Attachments Assembly Overview, => [ Locking Flange Cover - Tightening
Specifications ] Fuel Tank With Attachments Assembly Overview.
Installation is in reverse order of removal, note the following:
• Secure all hose connections with hose clamps appropriate for the model.
- Check the backing pieces - 1 to 4 - on the chassis mounts for damage; replace if necessary.
- Coat the backing pieces with a silicone-free lubricant before installing the fuel tank.
CAUTION!
Danger of damaging the fuel line connections
• When removing the fuel tank chambers, make sure the connections hang on the body.
- Replace the left fuel tank chamber and carefully reinstall in reverse order.
- Press the left fuel tank chamber outward until the weld seam touches the sound insulation on the B-pillar.
- Place the wedge - 2 - directly on the left fuel tank chamber weld seam - arrow - and secure with tension strap - 1 -.
R8 Coupe
- First, mount the tension strap - 1 - in the center - arrows -.
- Then mount the left tension strap - 2 - - arrows -.
- Install secondary air injection pump.